Installation Instructions
Bulletin 1494V Variable Depth, Flange Operated Circuit Breaker Operating Mechanisms
For use with Circuit Breakers 140G-G, 140MG-G, 140G-H, 140MG-H, 140G-I, 140MG-I, 140G-J, 140MG-J, 140G-K, 140MG-K,
140G-M, 140MG-M, 140G-N, 140MG-N
(Cat 1494V-M70; 1494V-M71; 1494V-M72)
WARNING: To prevent electrical shock, disconnect from power source before installing or servicing. Follow NFPA 70E requirements. Install in suitable enclosure. Keep free from contaminants.
Installation, adjustments, putting into service, use, assembly, disassembly, and maintenance shall be carried out by suitably trained personnel in accordance with applicable code of practice. In case of malfunction or
damage, no attempts at repair should be made. The product should be returned to the manufacturer for repair. Do not dismantle the product.
Table of Contents
Page
Enclosure with Handle Cutout
1 - Locate Circuit Breaker Mechanism
2 - Handle Installation
3 - Cut Connecting Rod
4a - 140G-G, 140MG-G, 140G-I, 140MG-I Circuit Breaker Installation
4b - 140G-H, 140MG-H, 140G-J, 140MG-J Circuit Breaker Installation
4c - 140G-K, 140MG-K Circuit Breaker Installation
4d - 140G-M, 140MG-M Circuit Breaker Installation
4e - 140G-N, 140MG-N Circuit Breaker Installation
5 - Connecting Rod and Mechanism Adjustment Procedure
2
2
3
3
4
6
7
8
11
Enclosure without Handle Cutout
6- Locating and Installing Door Catch
7- Locating and Drilling Handle Holes
8- Circuit Breaker Testing
12
13
14
Accessory List
15
Variable Depth, Flange Operated Circuit Breaker Mechanisms
2
Enclosure with Handle Cutout
1
Locate Circuit Breaker Mechanism
BB
CC1
AA
EE
AA
BB
CC1
CC2
DD
EE
Wire
Bending
Space
140G-G / 140MG-G
140G-H / 140MG-H
140G-I / 140MG-I
140G-J / 140MG-J
5/16"
1 - 41/64"
3"
3 - 1/2"
7 - 1/2"
6”
140G-K / 140MG-K
29/64”
1 - 47/64”
4"
4 - 1/2"
9 - 5/16"
12”
140G-M / 140MG-M
4 - 1/2"
4 - 1/32"
5"
5"
13 - 1/2"
12”
140G-N / 140MG-N
4 - 1/2"
4 - 1/32"
5"
5"
13 - 1/2"
12”
Frame
Size
DD
CC2
2
Handle Installation
1
2
Install gasket.
Install handle and spring bracket.
3
Install defeater lever.
1494F-M1, -P1 or -S1
30-40 lb-in
7-11 lb-in
1494F-M2 or -S2
60-80 lb-in
7-11 lb-in
IMPORTANT: Apply grease to O-Ring
to retain into handle groove.
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Variable Depth, Flange Operated Circuit Breaker Mechanisms
Enclosure with Handle Cutout (Cont’d)
3
Cut Connecting Rod
1
2
N
Enclosure
Working Depth
(Flange to
Mounting Plate)
3
Rod Cut
Connecting Rod
Catalog Number
Circuit Breaker
Mechanism
Circuit Breaker
Frame
1494V-M70
140G-G / 140MG-G
140G-I / 140MG-I
140G-H / 140MG-H
140G-J / 140MG-J
1494V-RA4
1494V-RB4
Rod Cut
N - 3-1/2"
N - 4"
1494V-M71
140G-K / 140MG-K
N - 4-1/2"
1494V-M72
140G-M / 140MG-M
140G-N / 140MG-N
N - 3-3/4”
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Variable Depth, Flange Operated Circuit Breaker Mechanisms
4
Circuit Breaker Installation
4a
140G-G; 140MG-G; 140G-I; 140MG-I
1
Verify that the disconnect handle and toggle on
the circuit breaker are in the “OFF” position.
2
Rotate connecting rod into drive bar
(10) full turns of engagement.
3
4
Install circuit breaker operating
mechanism into panel.
Choose proper insulation barrier
as labeled. Bend side panels of
insulation barrier inward.
140G-I
140G-J
140G-G
140G-H
R
140G-G
140G-I
140G-H
140G-J
23 - 37 lb-in
Remove liner from two-sided tape.
6
Align holes on insulation barrier with holes on operating mechanism.
7
Press firmly in place.
9
Attach toggle adjustment plate.
TAPE
5
L
L
23 - 37 lb-in
8
Install circuit breaker onto insulation barrier and mechanism.
10 lb-in
Go to Page 11 to assemble connecting rod and springs to handle
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Variable Depth, Flange Operated Circuit Breaker Mechanisms
5
Circuit Breaker Installation (Cont'd)
4b
140G-H; 140MG-H; 140G-J; 140MG-J
Reposition bail mechanism
Installation
Removal
1
8
2
4
7
L
L
3
L
5
L
6
10
Verify that the disconnect handle and toggle on
the circuit breaker are in the “OFF” position.
11
Install circuit breaker operating
mechanism into panel.
12
Rotate connecting rod into drive bar
(10) full turns of engagement.
140G-I
140G-J
140G-G
140G-H
140G-G
140G-I
R
R
9
140G-H
140G-J
23 - 37 lb-in
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PN-242292 DIR 10000787413 (Version 04)
Choose proper insulation barrier
as labeled. Bend side panels of
insulation barrier inward.
6
Variable Depth, Flange Operated Circuit Breaker Mechanisms
Circuit Breaker Installation (Cont'd)
4b 140G-H; 140MG-H; 140G-J; 140MG-J
Cont'd
Remove liner from two-sided tape.
14
Align holes on insulation barrier with holes on operating mechanism.
17
Attach toggle adjustment plate
TAPE
13
L
L
L
L
23 - 37 lb-in
15
Press firmly in place.
16
Install circuit breaker onto insulation barrier and mechanism.
10 lb-in
Go to Page 11 to assemble connecting rod and springs to handle
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Variable Depth, Flange Operated Circuit Breaker Mechanisms
Circuit Breaker Installation (Cont'd)
4c
140G-K; 140MG-K
Verify that the disconnect handle and toggle on
the circuit breaker are in the “OFF” position.
2
Rotate connecting rod into drive bar
(10) full turns of engagement.
3
Install circuit breaker operating
mechanism into panel.
R
R
1
40 - 60 lb-in
Install insulation barrier (provided with circuit breaker).
4
Remove liner from two-sided tape.
5
Align holes on insulation barrier with holes on operating mechanism.
Attach toggle adjustment plate
TAPE
8
L
L
L
L
23 - 37 lb-in
17 lb-in
6
Press firmly in place.
7
Install circuit breaker onto
insulation barrier and mechanism.
Go to Page 11 to assemble connecting rod and springs to handle
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Variable Depth, Flange Operated Circuit Breaker Mechanisms
Circuit Breaker Installation (Cont'd)
4d
140G-M; 140MG-M
1
Verify that the disconnect handle and toggle on
the circuit breaker are in the “OFF” position.
2
Rotate connecting rod into drive bar
(10) full turns of engagement.
3
Install circuit breaker operating
mechanism into panel.
90 - 130 lb-in
Install insulation barrier (provided with circuit breaker).
4
Remove liner from two-sided tape.
5
Align holes on insulation barrier with holes on operating mechanism.
8
Attach toggle adjustment plate
TAPE
8
40 - 60 lb-in
6
Press firmly in place.
7
Install circuit breaker onto
insulation barrier and
mechanism.
17 lb-in
Go to Page 11 to assemble connecting rod and springs to handle
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Variable Depth, Flange Operated Circuit Breaker Mechanisms
9
Circuit Breaker Installation (Cont'd)
4e
140G-N; 140MG-N
Reposition bail mechanism
4
40 - 60 lb-in
1
40 - 60 lb-in
5
6
23 - 37 lb-in
2
3
7
Verify that the disconnect handle
and toggle on the circuit breaker
are in the “OFF” position.
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8
Rotate connecting rod into drive
bar (10) full turns of engagement
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Variable Depth, Flange Operated Circuit Breaker Mechanisms
Circuit Breaker Installation (Cont'd)
4e
140G-N; 140MG-N
Install insulation barrier (provided with lugs).
Cont'd
9
Install circuit breaker operating
mechanism into panel.
10
Remove liner from two-sided tape.
11
Align holes on insulation barrier with holes on operating mechanism.
12
Press firmly in place.
13
Install circuit breaker
onto insulation barrier
and mechanism.
TAPE
90 - 130 lb-in
L
14
Attach toggle adjustment plate.
22 lb-in
40 - 60 lb-in
Go to Page 11 to assemble connecting rod and springs to handle
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Variable Depth, Flange Operated Circuit Breaker Mechanisms
Connecting Rod and Spring Assembly to Handle
5
Hitch Pin
Connecting
Rod
2
2
1
1
L
L
Primary Link
3
L
L
4
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Variable Depth, Flange Operated Circuit Breaker Mechanisms
12
Enclosure without Handle Cutout
6
Locating and Installing Door Catch
· Provided with projections for welding.
· Projections can also be used as a guide for drilling holes.
· Can be used as a template to drill corresponding holes in the enclosure door.
· User to supply the hardware for fastening the bracket.
· Fasteners must provide the degree of ingress protection for the environmental rating of the enclosure.
· The bracket hardware must be inaccessible to unauthorized personnel.
· Dimension K (3/4" to 1")
· When using large disconnect handle kit only (1494F-M2 or -S2), use door catch provided with handle kit.
· When using large disconnect handle kit and small door hardware kits (1494V-L1, -LL1, -L2 or -LL2), use door catch provided with door
hardware kit.
· Dimension K (1-1/8" to 1-3/8")
· When using large disconnect handle kit only (1494F-M2 or -S2), use door catch (40492-080-02) which can be ordered from factory.
· When using large disconnect handle kit and large door hardware kits (1494V-L3 or -LL3), use door catch provided with door hardware kit.
Door Catch
Mounting Bracket
Top
22 - 37 lb-in
Door Catch
TOP VIEW
Flange
Thickness
Enclosure Door
K
Door Catch
Mounting Bracket
C
Enclosure
Base
Door Catch
D
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B
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Variable Depth, Flange Operated Circuit Breaker Mechanisms
13
Enclosure without Handle Cutout
· Enclosures with a Flange Thickness less than 3/16" use dimensions below to install disconnect handle.
· Enclosures with a Flange Thickness 3/16" and greater use dimensions in Alternate Mounting Kit 1494V-H6 to install disconnect handle.
7
Locating and Drilling Handle Holes
C
C
B
B
A
A
(2) .328 Dia.
Holes
G
E
E
(2) .265 Dia.
Holes
Square corners
or up to
1/4" radius
H
G
Door Catch
Mounting
Bracket
F
J
D
Door Catch
Mounting
Bracket
1/2"
D
1/4"
H
To make slot
drill (3) 1/2"
diameter holes
and remove burrs
Figure 1
FRAME
HANDLE
140G-G, H
140MG-G, H
140G-I, J
140MG-I, J
140G-K
140MG-K
140G-M
140MG-M
140G-N
140MG-N
1494F-M1
(Figure 1)
1494F-M1
(Figure 1)
1494F-M1
(Figure 1)
1494F-M2
(Figure 2)
1494F-M2
(Figure 2)
F
H
Figure 2
A
(MIN)
B
(MIN)
C
(MAX)
D
E
F
G
H
J
3-1/2”
29/32”
1-3/32”
1-5/8”
2-11/32”
4-11/16”
1-9/16”
1”
7/8”
10-29-32”
29/32”
1-3/32”
1-5/8”
2-11/32”
4-11/16”
1-9/16”
1”
7/8”
13-3/32”
29/32”
1-3/32”
1-5/8”
2-11/32”
4-11/16”
1-9/16”
1”
7/8”
17-5/16”
1-3/8”
1-3/32”
2”
3-23/32”
6-1/2”
5/16”
5-1/2”
NA
21-7/8”
1-3/8”
1-3/32”
2”
3-23/32”
6-1/2”
5/16”
5-1/2”
NA
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8
Variable Depth, Flange Operated Circuit Breaker Mechanisms
Testing of Circuit Breaker
Connecting Rod
Hitch Pin
Spring
Handle Link
L
L
Defeator
Lever
Toggle Adjustment Plate
140G / MG-G, H, I, J
140G / MG-K
140G / MG-M
140G / MG-N
23 - 37 lb-in
40 - 60 lb-in
“ON” Position
1. Move defeater lever down and move handle to the ON position.
2. If the circuit breaker does not turn “ON”, loosen (2) screws on toggle adjustment plate.
3. Move toggle adjustment plate toward line terminals.
4. Tighten the (2) toggle adjustment plate screws to torque value in table above.
5. If the circuit breaker still can not be turned “ON”, return handle to the OFF position.
6. Unhook spring, remove hitch pin and separate connecting rod from handle link.
7. Turn connecting rod one full turn clockwise.
8. Reattach connecting rod and handle link, hitch pin and spring.
9. If the circuit breaker still can not be turned “ON”, repeat Steps 6, 7 and 8 if necessary.
“OFF” Position
1.
2.
3.
4.
5.
Move handle to the “OFF” position.
If the cirucit breaker does not turn “OFF”, unhook spring, remove hitch pin and separate connecting rod from handle link.
Turn connecting rod one full turn clockwise.
Reattach connecting rod and handle link, hitch pin and spring and then retest.
If the circuit breaker still can not be turned “OFF”, repeat steps 2, 3 & 4.
“RESET” Position
1.
2.
3.
4.
5.
6.
Manually trip the circuit breaker while in the “ON” position.
Move handle to the “OFF” position to reset.
If circuit breaker does not reset, unhook spring, remove hitch pin and separate connecting rod from handle link.
Adjust connecting rod by turning it clockwise 1-2 turns and then retest.
Repeat steps 1-4 until circuit breaker resets.
Verify that the circuit breaker can be turned “ON”, “OFF” and “RESET” following the steps above.
NOTE: Twisting of the bail mechanism is acceptable when the handle is in the full “ON” or full “OFF” position.
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Variable Depth, Flange Operated Circuit Breaker Mechanisms
Components
Cat No.
Description
Circuit Breaker
1494F-M1
1494F-P1
1494F-S1
5-1/2" Painted Metal Handle
5-1/2" Molded Handle
5-1/2" Stainless Steel Handle
140G-G, 140MG-G
140G-H, 140MG-G
140G-I, 140MG-I
140G-J, 140MG-J
140G-K, 140MG-K
1494F-M2
1494F-S2
7-1/2" Painted Metal Handle
7-1/2" Stainless Steel Handle
140G-M, 140MG-M
140G-N, 140MG-N
1494V-RA4
Connecting Rod
Enclosure Working Depth: 6-3/4" to 23"
140G-G, 140MG-G
140G-H, 140MG-G
140G-I, 140MG-I
140G-J, 140MG-J
140G-K, 140MG-K
1494V-RB4
Standard Connecting Rod
Enclosure Working Depth: 6-3/4" to 23"
140G-M, 140MG-M
140G-N, 140MG-N
1494V-M70
Circuit breaker mechanism
140G-G, 140MG-G
140G-H, 140MG-G
140G-I, 140MG-I
140G-J, 140MG-J
1494V-M71
Circuit breaker mechanism
140G-K, 140MG-K
1494V-M72
Circuit breaker mechanism
140G-M, 140MG-M
140G-N, 140MG-N
1495-N85
(1) N.O. Auxiliary Contact
1495-N86
(1) N.C. Auxiliary Contact
1495-N87
140G-G, 140MG-G
140G-H, 140MG-G
140G-I, 140MG-I
140G-J, 140MG-J
Insulation Kit
Publication 1494V-IN105E-EN-P - September 2014
140G-G, 140MG-G
140G-H, 140MG-G
140G-I, 140MG-I
140G-J, 140MG-J
140G-K, 140MG-K
140G-M, 140MG-M
140G-N, 140MG-N
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15
Bulletins: 507, 513, 513H, 523E, 523F, 523G, 1233, 1233X, 1233V
NEMA
Starter
Size
Horsepower Rating
For Combination Starter
0
1
2
3
4
5
1/10..1/3 HP
1/10…1 HP
1/10…1 HP
1/2…1 HP
1-1/2…3 HP
1-1/2…3 HP
1-1/2…3 HP
5 HP
5 HP
1/10…1/3 HP
1/10…1 HP
1/10…1 HP
1/2…1 HP
1-1/2…3 HP
1-1/2…3 HP
1-1/2…3 HP
5 HP @ 200V
5…7-1/2 HP
5…7-1/2 HP
5…7-1/2 HP
5…7-1/2 HP
10 HP
10 HP
10 HP
15 HP
15 HP
15 HP
20…25 HP
20…25 HP
15…25 HP
30 HP
30 HP
30…50 HP
40…50 HP
30 HP
40…50 HP
60 HP
60…75 HP
100 HP
75…100 HP
50 HP
60 HP
75 HP
60…75 HP
100 HP
125 HP
125…150 HP
200 HP
150…200 HP
Voltage
200V - 230V
460V
575V
200V - 230V
460V
575V
200V - 230V
460V
575V
200V - 230V
460V
575V
200V - 230V
460V
575V
200V - 230V
200V
460V
575V
230V
200V
460V
575V
200V - 230V
460V
575V
230V
460V
575V
200V - 230V
575V
230V
460V
575V
200V
200V - 230V
575V
460V
575V
200V
230V
575V
460V
575V
Circuit
Breaker
Rating
Circuit Breaker
Cat No.
15A
140MG-G8P-C15
30A
140MG-G8P-C30
15A
140MG-G8P-C15
30A
50A
140MG-G8P-C30
140MG-G8P-C50
30A
140MG-G8P-C30
50A
140MG-G8P-C50
30A
140MG-G8P-C30
100A
140MG-G8P-D10
50A
140MG-G8P-C50
100A
50A
150A
140MG-G8P-D10
140MG-G8P-C50
140MG-J8P-D15
100A
140MG-G8P-D10
150A
200A
100A
150A
200A
150A
250A
300A
400A
300A
400A
200A
300A
400A
300A
140MG-J8P-D15
140MG-J8P-D20
140MG-G8P-D10
140MG-J8P-D15
140MG-J8P-D20
140MG-J8P-D15
140MG-J8P-D25
140MG-K8P-D30
140MG-K8P-D40
140MG-K8P-D30
140MG-K8P-D40
140MG-J8P-D20
140MG-K8P-D30
140MG-K8P-D40
140MG-K8P-D30
Note: Contact Rockwell Automation for circuit breaker use in bulletin 503 and 503L.
Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page.
Allen-Bradley, Rockwell Software, and Rockwell Automation are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Publication 1494V-IN105E-EN-P - September 2014
PN-242292
DIR 10000787413 (Version 04)
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.